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Solution

qontrol steelmaking

Short Desription

In this project, qoncept realized a fully integrated software system covering both process automation and operating management functionalities to optimize the entire value chain from scrap to the finished cast ingot. Based on the qontrol framework, the solution seamlessly integrates all major steelmaking steps (Scrap Yard, EAF, LF, V(O)D, and Ingot Casting) into one extensible digital platform.

At Level 2, the system ensures real-time process monitoring and control. Dedicated operator workstations and software provide direct interaction with the equipment, while dynamic setpoint control and delay tracking secure stable and efficient operations. All relevant process data are captured at Level 1, transferred to Level 2, and managed in real time to ensure precise production execution.

On the MES level, the solution manages production workflows, optimizes metallurgical processes, and integrates higher-level planning. Key modules include raw material optimization, order and line-up management, master data management for steel grades and treatments, as well as recipe handling for melting, refining, and degassing. Additional features such as stockyard management, reporting, and advanced delay tracking provide full traceability and actionable insights.

The result is a comprehensive, future-proof software system that delivers end-to-end transparency, optimized resource utilization (qontrol maps included), and significantly improved efficiency across the entire EAF steelmaking process chain.

Solution

qontrol steelmaking

Short Desription

In this project, qoncept started the implementation of its qontrol maps software in a foundry. The introduction began as an off-line solution for charge optimization and was gradually expanded with coupling to SAP and the full integration of the scrap yard. The cost-optimized charge calculation generated measurable savings, which supported the further rollout of the software integration.

Building on this foundation, the system was extended to cover the EAF, two induction furnaces (IF), an AOD, and the casting shop. With seamless integration into the IT landscape, the solution combines office applications for product definitions, order planning, charge preparation, production overview, and reporting with shop floor applications for real-time process monitoring and operator interaction.

At the process control level, the software ensures process data acquisition, heat and material tracking, real-time monitoring of metallurgical operations, and dynamic setpoint control. By linking advanced metallurgical models with practical operator guidance, the system standardizes process know-how, ensures secure material supply, and improves resource efficiency across the foundry’s value chain.

Solution

qontrol customized

Short Desription

In this project, qoncept implemented a software system to seamlessly integrate the final processing of flat steel into the customer’s IT landscape. The system, based on the qontrol framework, covers the complete workflow from order preparation to pallet handling and ensures reliable monitoring and control of all production steps.

At Level 2, the solution provides real-time process monitoring and control. It records and processes cyclical data and events, transmits setpoints to Level 1.5 systems, and observes production steps through an integrated camera system. Downtime and error tracking are managed in real time, while live production status updates provide operators with full transparency across all units.

At the MES level, the software enables structured production management and data integration. Functions include master data management of products, materials, storage locations, equipment, and manufacturing specifications. Orders received from the ERP system are prepared, sequenced, and released for production through fine planning. Product and material tracking, combined with reporting interfaces for external systems, ensures end-to-end traceability and operational efficiency.

With its modular design and deep IT integration, the solution establishes a digital backbone for the final processing of flat steel, supporting optimized workflows, consistent data flows, and improved production reliability.

Solution

qontrol MES

Short Description

At a leading Austrian steel producer, qoncept implemented a new software system to replace paper-based workflows in the finishing area. Building on a comprehensive requirement specification previously defined by qoncept, the system digitally maps and controls all processes from order intake to final delivery.

The solution integrates both Level 2 and MES functionalities. At process level, it captures and processes real-time data, provides online system monitoring, and enables direct process control. At the MES level, it manages master data, production planning and sequencing, material and product tracking, as well as quality assurance and reporting. Advanced analytics, KPI monitoring, and downtime tracking support continuous improvement and greater operational transparency.

With its modular architecture and seamless integration into the existing IT landscape, the system ensures full product traceability, higher efficiency, and a solid digital foundation for future expansions in the finishing area.

Solution

qurve

Short Desription

In this project, qoncept delivered a fully integrated and automated solution for tracking and optimizing the scrap handling and charging process in an electric arc furnace (EAF) steel plant. Together with our customer, we implemented a system that captures all material movements from the arrival of scrap at the plant to its final charging into the EAF.

At the core of this solution is qurve: our intelligent sensor/camera system purpose-built for steel plant environments. It integrates high-performance imaging, embedded software for real-time analysis, and robust mechanical design including cooling and protective housing to ensure reliable operation under extreme conditions. Multiple qurve units were strategically installed at key points in the process to achieve the following objectives:

  • Detection of the number and position of incoming scrap railway wagons
  • Precise localization of both scrap charging cranes using a unique camera-based positioning method

By integrating data from all qurve sensors with additional signals from the scrap charging cranes and scrap bucket transfer cars, we enabled complete tracking and real-time reporting of all scrap charging operations.

This fully automated solution allowed the customer to (1) gain full transparency into the scrap handling process, (2) optimize the performance and control of the EAF and (3) improve scrap logistics and supply chain management.

Focus Area

  • Scrap Yard Management and Charge Design
  • EAF/IF Performance Optimization

Short Description

For this project, qoncept evaluated the existing scrap classification and electric arc furnace (EAF) performance in order to increase process stability and reduce material-related production costs. Using historical production data, key indicators of EAF efficiency and melt predictability were analyzed. The study identified significant variability within existing scrap categories and assessed their impact on alloying effort and operational performance. As a result, a refined classification concept was developed, providing the basis for more consistent melt compositions and improved material logistics. The findings support both immediate and mid-term actions for optimizing resource use and furnace operation.

Focus Area

  • Production Route Design, Logistics & Tendering Support

Short Description

For this project, qoncept conducted an on-site audit to evaluate storage technologies, internal transport flows, digitalization level, and external logistics interfaces at a steel production facility. The assessment focused on identifying inefficiencies related to unstructured storage strategies, manual data handling, and space utilization. Through detailed analysis of warehouse data and transport patterns, key areas for operational improvement were identified. The results form the basis for a prioritized set of measures to reduce truck loading times, optimize storage space, and improve logistics performance.

Focus Area

  • Strategic Metallurgy & Process Development

Short Description

For this project, qoncept conducted an on-site fact-finding mission to assess the readiness of an integrated steel plant for the production of advanced alloyed materials. The evaluation covered the entire process chain, including melting, casting, forging, rolling, and remelting operations. Particular focus was placed on the alignment between equipment, process design, and product requirements. The analysis identified key challenges in achieving consistent product quality and process stability, especially when applying high-complexity alloys in a high-throughput production environment. Additional aspects included the feasibility of producing forged and remelted components, as well as the current level of process control in secondary and special metallurgy. The results form the basis for a structured roadmap aimed at stabilizing existing production routes and preparing the facility for the reliable manufacture of advanced materials.

Focus Area

  • Strategic Metallurgy & Process Development

Short Description

For this project, qoncept provided strategic and technical consulting to support the production of ferrovanadium from vanadium-rich steelmaking slag. Since the raw material must meet strict chemical requirements, the project focused on developing the metallurgical and operational know-how required to identify and qualify suitable slag sources. In addition to technical expertise, qoncept supported the client in research activities, supplier engagement, and the preparation of technically sound business plans. The work included direct discussions with potential steel producers to evaluate collaboration opportunities and ensure supply chain feasibility.

Focus Area

  • Strategic Metallurgy & Process Development

Short Description

For this project, qoncept conducted an on-site fact-finding mission to evaluate the technical readiness and equipment capabilities of an integrated steel plant aiming to enter the electrical steel market. The evaluation included equipment condition, operational practices, metallurgical flexibility, and potential upgrade needs. Based on the analysis, three families of electrical steel grades were defined according to their chemical composition and process requirements. The study confirmed that the existing set-up can produce certain grades with medium silicon content, while the newl planned shop is capable of handling more demanding grades with low carbon and high silicon content. In addition to outlining feasible production routes, qoncept recommended targeted investments to support a stable and efficient production ramp-up.